Expansion Block/Orifice Tube: Service and Repair

Evaporator Core Orifice

Removal

1. Remove the engine cover.
2. Evacuate the A/C system.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

3. Raise and support the vehicle.
4. Drain the cooling system.
5. Remove the driver side front seat.
6. Remove the instrument panel upper section.
7. Release the 3 ground cables from the driver side lower A-pillar.
^ Remove the 2 nuts.






8. Disconnect the 5 electrical connectors from the driver side lower A-pillar.






9. Release the 3 ground cables from the passenger side lower A-pillar.
^ Remove the 2 nuts.





10. Disconnect the 5 electrical connectors from the passenger side lower A-pillar.
11. Disconnect the heater motor electrical connector.





12. Disconnect 2 central junction box (CJB) electrical connectors.





CAUTION: Cover fibre optic cable connectors to minimise dust ingress and avoid bending the cables in a radius of less than 30 mm.

13. Disconnect 2 electrical connectors from the instrument panel center reinforcement.
14. If installed, disconnect the instrument panel center reinforcement fibre optic cables.
^ Disconnect the electrical connector.





15. Remove the heater housing center ducts.





16. Disconnect the steering column intermediate shaft from the steering column.
^ Note the fitted position.
^ Remove the special bolt and discard the nut.





17. Release the heater housing from the instrument panel carrier.
^ Remove the 7 Torx screws.





18. Remove the plenum chamber panel.
19. Remove the instrument panel carrier to bulkhead Torx bolt.





CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

20. With assistance, remove the instrument panel.
^ Remove the 6 Torx bolts.





21. Disconnect 2 heater hoses from the bulkhead.
^ Release the 2 clips.





CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.

22. Release 2 A/C lines from the body.
^ Remove the nut.

23. Release 2 A/C lines from the bulkhead.
^ Remove the bolt.
^ Remove and discard the O-ring seals.





24. Remove the 2 adapter panels.
^ Remove the 4 nuts.





25. Disconnect 2 drain tubes from the heater housing.





26. Remove the driver side footwell duct.
^ Remove the 2 Torx screws.





27. Remove the passenger side footwell duct.
^ Remove the 2 Torx screws.





28. Driver side: Remove the heater housing to bulkhead Torx bolt.





29. Passenger side: Remove the heater housing to bulkhead Torx bolt.





30. Remove the heater housing.
31. Disconnect the evaporator core temperature sensor electrical connector.
32. Release the heater core housing.
^ Remove the 2 screws.
^ Remove the 8 clips.





33. Remove the evaporator core.
^ Release the temperature sensor.





Installation

1. Install the evaporator core.
^ Secure the temperature sensor.
2. Secure the heater core housing.
^ Install the clips.
^ Tighten the screws.
3. Connect the temperature sensor electrical connector.
4. Install the heater housing.
5. Passenger side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).
6. Driver side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).
7. Install the footwell ducts.
^ Tighten the Torx screws.
8. Connect the drain tubes to the heater housing.
9. Install the adapter panels.
^ Tighten the nuts to 6 Nm (4 lb.ft).
10. Secure the A/C lines to the bulkhead.
^ Clean the components.
^ Install new O-ring seals.
^ Tighten the bolt to 6 Nm (4 lb.ft).
11. Secure the A/C lines to the body.
^ Tighten the nut to 6 Nm (4 lb.ft).
12. Connect the bulkhead heater hoses.
13. With assistance, install the instrument panel.
^ Tighten the Torx bolts to 25 Nm (18 lb.ft).
14. Install the instrument panel carrier to bulkhead Torx bolt and tighten to 25 Nm (18 lb.ft).
15. Install the plenum chamber panel.
16. Secure the heater housing.
^ Tighten the screws.
17. Connect the steering column intermediate shaft.
^ Install the special bolt and tighten the new nut to 22 Nm (16 lb.ft).
18. Install the heater housing center ducts.
19. Connect the instrument panel center reinforcement fibre optic cables.
20. Connect the instrument panel center reinforcement electrical connectors.
21. Connect the CJB electrical connectors.
22. Connect the heater motor electrical connector.
23. Connect the electrical connectors to the passenger side lower A-pillar.
24. Connect the ground cables to the passenger side lower A-pillar.
^ Tighten the nuts to 10 Nm (7 lb.ft).
25. Connect the electrical connectors to the driver side lower A-pillar.
26. Connect the ground cables to the driver side lower A-pillar.
^ Tighten the nuts to 10 Nm (7 lb.ft).
27. Install the instrument panel upper section.
28. Install the front seat.
29. Recharge the A/C system.
30. Refill the cooling system.
31. Install the engine cover.